Method of producing sole for bending-actuated aerated footwear

ABSTRACT

A method of producing a sole assembly for manufacturing aerated footwear comprises: fabricating a sole component having an aperture extending from a top surface to a bottom surface, and having recessed cavity along a length of the bottom surface, the aperture connecting to the recessed cavity; attaching a material layer to the recessed cavity; attaching an actuation member to the material layer; and closing the aperture with a valve so as to control the entry of and expulsion of air from the recessed cavity.

CROSS REFERENCE TO RELATED APPLICATION

The present Application is related to Provisional Patent Application entitled “Method of Producing Sole for Bending Actuated Aerated Footwear” filed 11 Oct. 2012 and assigned filing No. 61/712,271, incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a method of producing a sole, midsole or insole for bending actuated aerated footwear in which a top layer contains an aperture for a valve or valve assembly and a flat membrane or layer of material serves as a pumping member for circulating air in response to bending or unbending of the sole.

BACKGROUND OF THE INVENTION

The concept of bending actuated aerated footwear is known in the present state of the art. Although producing a “functional” pair of bending actuated aerated footwear is not difficult, producing a pair at a low cost, with a thin profile and with consistent high performance is significantly more difficult.

BRIEF SUMMARY OF THE INVENTION

In one aspect of the present invention, a method of producing a sole assembly comprises: fabricating a first sole component having a top surface and a bottom surface, the first sole component further having an aperture extending through the top surface, the first sole component further having recessed cavity along a length of the bottom surface such that the aperture connects to the recessed cavity; attaching a material layer proximate an edge of the recessed cavity so as to partially close the recessed cavity; attaching an actuation member to the material layer; and covering the aperture with a valve so as to substantially close the recessed cavity.

In another aspect of the present invention, a method of producing a sole assembly or a midsole component for aerated footwear comprises: fabricating a first sole component having a surface, the first sole component further having recessed cavity along a length of the surface; attaching a material layer proximate an edge of the recessed cavity so as to close the recessed cavity partially from a first side of the recessed cavity; attaching an elongate actuation member to the material layer; fabricating a second sole component having an aperture extending therethrough and attaching a valve to the aperture so as to close the recessed cavity from a second side of the recessed cavity; attaching the second sole component to the first sole component to produce the sole assembly, such that the material layer and the actuation member are enclosed between the first sole component and the second sole component.

The additional features and advantage of the disclosed invention is set forth in the detailed description which follows, and will be apparent to those skilled in the art from the description or recognized by practicing the invention as described, together with the claims and appended drawings.

BRIEF DESCRIPTIONS OF THE DRAWINGS

The invention can be better understood by referencing the following figures and descriptions. Note that the figures are not necessarily to scale and are intended primarily to illustrate the concepts of the invention. The foregoing aspects, uses, and advantages of the present invention will be more fully appreciated as the same becomes better understood from the following detailed description of the present invention when viewed in conjunction with the accompanying figures, in which:

FIG. 1 shows a top view of a sole component having an aperture therethrough, in accordance with the present invention;

FIG. 2 shows a bottom view of the sole component of FIG. 1, showing a recessed cavity;

FIG. 3 shows a cross sectional view of the sole component of FIG. 2;

FIG. 4 shows a bottom view of the sole component of FIG. 2 with a material layer disposed over the recessed cavity;

FIG. 5 shows a bottom view of the sole component of FIG. 2 with an actuation member disposed on the material layer;

FIG. 6 shows a bottom view of the sole component of FIG. 2 with a bottom sole component disposed on the bottom surface of the sole component;

FIG. 7 shows a top view of a complete sole assembly, with a valve disposed in the aperture;

FIG. 8 shows a cross sectional view of the complete sole assembly of FIG. 7;

FIG. 9 shows a cross sectional view of a complete sole assembly similar to that in FIG. 8 but as assembled from the top;

FIG. 10 shows a cross sectional view of a complete sole assembly where an actuation member is attached above a thin layer of material;

FIG. 11 shows a boot having a molded sole with a complete sole assembly;

FIG. 12 shows a sectional view of the boot of FIG. 10; and,

FIG. 13 shows a boot having a complete sole assembly inserted into a prefabricated sole of an article of footwear.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention.

The present invention relates generally to a method of producing bending actuated aerated footwear that provide a high level of air circulation while comprising a relatively thin cross section, is inexpensive to produce, and provides for consistency in manufacture.

In particular, the disclosure details production methods of producing or assembling soles for such types of footwear. There are disclosed three general embodiments of a method for producing a sole assembly for bending-actuated, aerated footwear: In a first embodiment, the sole is produced by a method denoted as “assembled from the bottom.” In a second embodiment, the sole is produced by a method denoted as “assembled from the top.” In a third embodiment, the assembled sole is configured as a subassembly, that is, configured as an insert for user or manufacturer placement over a conventional sole in an item of footwear, or provided as a component configured for insertion into a prefabricated sole, during fabrication of the corresponding article of footwear. Accordingly, the disclosed embodiments provide for methods of achieving bending-actuated aeration within an item of footwear as the user walks or otherwise applied a bearing force to the sole.

In the embodiment of assembling from the bottom, a first sole or midsole component is provided, and the remaining sole components are attached to the bottom surface of the first sole or midsole component. The first sole, or midsole component, is generally the top-most component of the sole or the midsole component, and is preferably formed or molded such that the top of the first sole or midsole component has an aperture, and the bottom of the first sole or midsole component has a large recess or cavity along a length. Preferably the aperture connects through to the bottom of the cavity. More preferably this cavity is disposed at a midsection of the first sole or midsole component. Additionally the first sole or midsole component is fitted with at least two air passageways which are preferably molded into the first sole or midsole component.

In the embodiment of assembling from the top, a first sole component or a midsole component is provided, with a recess or cavity at its top. Additional sole components are attached to the top surface of the first sole component or midsole component. Along the edges of the cavity or near the edges, a thin layer of material or membrane can be attached thus separating the cavity from the outside. An actuation member may be attached to the thin layer of material, on either an above surface or on a lower surface, on one end of the actuation member, and to the front of either lower or upper part of the sole on the other end of the actuation member. A valve or vale arrangement may be mounted or attached to an aperture in the first sole component or a midsole component to produce a completed sole assembly.

As shown in FIGS. 1 and 2, a first sole component 100 comprises a generally circular aperture 106 and an elongated recessed cavity 108. The first sole component 100 is formed or molded such that the aperture 106 is disposed in a top surface 102 of the first sole component 100. A bottom surface 104 of the first sole component 100 contains the recessed cavity 108 disposed along the length of the first sole component 100.

Preferably, the recessed cavity 108 is disposed in a midsection region 120 of the first sole component 100, that is, the region located under the arch of a wearer's foot. Specifically, the midsection 120 extends from a heel section 122 into a ball section 124 of the first sole component 100, where the heel section 122 is the region located under the heel of a wearer's foot and the ball section 124 is the region located under the ball of the wearer's foot.

The aperture 106 is positioned in the top surface 102, generally opposite the recessed cavity 108, such that at least a portion of the aperture 106 extends into the recessed cavity 108. In the example provided, the recessed cavity has a cavity perimeter 126 generally in the shape of a paddle or trowel.

FIG. 3 shows a cross sectional view of the first sole component 100 as cut along section line 3-3 shown in FIG. 2. It can be seen in the illustration that the aperture 106 extends downward from the top surface 102 into the recessed cavity 108, and that the recessed cavity 108 extends upward from the bottom surface 104.

As shown in FIG. 4, a material layer 110 is attached to the bottom surface 104 of the first sole component 100. The material layer 110 has a material layer perimeter 128 generally in the shape of a rectangle with concave long sides. Accordingly, the material layer 110 is shaped and sized so as to cover essentially the entire cavity perimeter 126 of the recessed cavity 108. This configuration functions to close off the aperture 106 (not shown) from the bottom surface 104 of the first sole component 100.

The material layer 110 includes a plurality of surface grooves 130 oriented and disposed in the material layer 110 so as to allow for the easy flexing of the material layer 110 in general conformance to the bending of the wearer's foot. An actuation member 112, shown in FIG. 5, can then be attached to the material layer 110. The actuation member 112 is configured as an elongated strip having approximately the length of the recessed cavity 108 such that, when placed over the material layer 110, the actuation member 112 is disposed generally over the recessed cavity 108. Preferably the actuation member 112 is an elongate member with its opposite end (the side not attached to the membrane above the cavity) residing in a front part of the sole 100.

In a final step, a bottom sole component 114 can then be attached to the first piece of sole by gluing, cementing or stitching, such that the actuation member 112 and the material layer 110 are covered by the bottom sole component 114, as shown in FIG. 6. In an exemplary embodiment, the actuation member 112 may comprise a springboard, a semi-rigid component, or a rigid component. At a subsequent point, a valve or valve arrangement 116 may be mounted into or onto the aperture 106 to form a complete sole assembly 140, as shown in FIG. 7.

A cross sectional view, across the section line 8-8 of the complete sole assembly 140, is shown in FIG. 8. It should be understood that the relative thickness of the complete sole assembly 140 has been exaggerated, relative to the width, to more clearly illustrate the component stack-up of the complete sole assembly 140. The material layer 110 covers a first opening of the recessed cavity 108 so as to partially close the recessed cavity. The actuation member 112 may be disposed against the material layer 110. The valve or valve arrangement 116 thus cooperates with the material layer 110 to substantially close the recessed cavity 108 by covering the aperture 106. Accordingly, the valve or valve arrangement 116, together with the material layer 110, functions to control ambient air entering and being expelled from the recessed cavity 108. The bottom sole component 114 is attached to the bottom surface 104 such that the actuation member 112 and the material layer 110 are covered by the bottom sole component 114.

Accordingly, when a user is wearing an item of footwear (see FIGS. 11-13, below) containing the complete sole assembly 140, the valve or valve arrangement 116 functions to: (i) allow ambient air to be expelled from the recessed cavity 108 when the user steps on a solid surface and applies a bearing force to the actuation member 12 by bending or flexing the footwear sole, and (ii) allow ambient air to re-enter the recessed cavity 108 when the item of footwear is raised from the solid surface. This repeated entry and expulsion of ambient air from the recessed cavity 108 functions to actuate air flow, that is, to provide bending-actuated aeration to the item of footwear, as the user walks or otherwise applied a bearing force to the complete sole assembly 140. This feature and action are also provided by insertion of the complete sole assembly 150 or the complete sole assembly 160, into any suitable item of footwear, as described below.

In an alternative embodiment, shown in FIG. 9, the order of attachment for the actuation member 112 and the thin layer of material 110 or membrane can be reversed. In a complete sole assembly 150, the actuation member 112 may be attached at a first end 132 to the material layer 110, and a second end 134 of the actuation member 112 may be attached to the bottom front part of the first sole component 100. In this manner, the actuation member 112 would be disposed above the material layer 110 when the actuation member 112 is subsequently sealed along its edges to the first sole component 100. It should be understood that the relative thicknesses of the complete sole assembly 150 components have been exaggerated to more clearly illustrate the stack up of the components.

FIG. 10 shows a complete sole assembly 160, similar to the complete sole assembly 140 shown in FIG. 8, but assembled from the top. It should be understood that the relative thicknesses of the individual components of the complete sole assembly 160 have been exaggerated to more clearly show assembly detail of the complete sole assembly 160. A bottom sole component 154 has a recessed cavity 158 at the top of the bottom sole component 154. Along the edges of the recessed cavity 158, or near to the edges of the recessed cavity 158, a thin layer of material 164 or membrane with surface grooves (similar to surface grooves 130, described above) can be attached, thus separating the recessed cavity 158 from the outside of the complete sole assembly 160. An actuation member 162 may be attached to the thin layer of material 164 do aid in the application of force from the foot of the user to deform the recessed cavity 158 and produce the expulsion of ambient air.

Just as in assembling from the bottom, described above, the order of the actuation member 162 and the thin layer of material 164 is reversible. A valve or valve arrangement 166 may then be mounted or attached to an aperture 168 in a top sole component 156, which is then attached to a top surface 172 of the bottom sole component 154. Accordingly, the valve or valve arrangement 166 operates together with the thin layer of material 164 to substantially close off the recessed cavity 158 and provide aeration to an item of footwear via the actuation member 162, as described above for the complete sole assemblies 140 and 150.

The complete sole assembly 140, the complete sole assembly 150, and the complete sole assembly 170 may each comprise a subsection, an insert, or a component of a larger sole or a shoe or other item of footwear. For example, a shoe manufacturer can decide to assemble the complete sole assembly 140 from the bottom, or assemble the complete sole assembly 150 from the bottom, or assemble the complete sole assembly 160 from the top, as described above, and then mold a larger sole around either the complete sole assembly 140, or the complete sole assembly 150, or the complete sole assembly 160. The selected assembly process may be followed to produce a rain boot 180, for example, as shown in FIGS. 11 and 12 with either the complete sole assembly 140, or the complete sole assembly 150, or the complete sole assembly 160, molded into the rain boot 180. It should be understood that any type of footwear, in place of the rain boot 180, may be manufactured using the disclosed processes.

Alternatively, the complete sole assembly 140, the complete sole assembly 150, or the complete sole assembly 160 could be utilized as a separate component, and then inserted into a boot 184, as shown in FIG. 13, or into a shoe (not shown), or into any similar item of footwear. In still another alternative embodiment, the complete sole assembly 140, the complete sole assembly 150, or the complete sole assembly 160 may be separately inserted into a prefabricated sole in the corresponding item of footwear. Emplacement of the complete sole assembly 140, or the complete sole assembly 150, or the complete sole assembly 160, in either configuration shown, provides for the entry and expulsion of ambient air from the recessed cavity 108 or the recessed cavity 158 to actuate or provide aeration as the user walks in and flexes the corresponding item of footwear.

It is to be understood that the description herein is only exemplary of the invention, and is intended to provide an overview for the understanding of the nature and character of the disclosed method of producing a sole for bending-actuated aerated footwear. The accompanying drawings are included to provide a further understanding of various features and embodiments of the method and devices of the invention which, together with their description serve to explain the principles and operation of the invention. 

What is claimed is:
 1. A method of producing a sole assembly or a midsole component for aerated footwear, said method comprising the steps of: fabricating a first sole component having a top surface and a bottom surface, said first sole component further having an aperture extending through said top surface, said first sole component further having recessed cavity along a length of said bottom surface such that said aperture connects to said recessed cavity; attaching a material layer proximate an edge of said recessed cavity so as to partially close said recessed cavity; attaching an actuation member to said material layer; and covering said aperture with a valve so as to substantially close said recessed cavity.
 2. A method of producing a sole assembly for aerated footwear as in claim 1 wherein a second sole component is attached to said first sole component such that said material layer is covered by said second sole component.
 3. A method of producing a sole assembly as in claim 1 wherein said actuation member comprises an elongate member.
 4. A method of producing a sole assembly as in claim 3 wherein said elongate member comprises at least one of a springboard, a semi-rigid component, or a rigid component.
 5. A method of producing a sole assembly as in claim 1 wherein said actuation member comprises a first end fixed to said sole component.
 6. A method of producing a sole assembly as in claim 5 wherein said actuation member comprises a second end fixed to said material layer.
 7. A method of producing a sole assembly as in claim 1 wherein said material layer comprises a plurality of surface grooves.
 8. A method of producing a sole assembly as in claim 1 wherein said first sole component comprises part of a molded sole.
 9. A method of producing a sole assembly as in claim 1 further comprising the step of inserting said sole assembly into a prefabricated sole of an article of footwear.
 10. A method of producing a sole assembly as in claim 1 wherein said valve functions to control ambient air entering and being expelled from said recessed cavity.
 11. A method of producing a sole assembly or a midsole component for aerated footwear, said method comprising the steps of: fabricating a first sole component having a surface, said first sole component further having recessed cavity along a length of said surface; attaching a material layer proximate an edge of said recessed cavity so as to close said recessed cavity partially from a first side of said recessed cavity; attaching an elongate actuation member to said material layer; fabricating a second sole component having an aperture extending therethrough and attaching a valve to said aperture so as to close said recessed cavity from a second side of said recessed cavity; attaching said second sole component to said first sole component to produce said sole assembly, such that said material layer and said actuation member are enclosed between said first sole component and said second sole component.
 12. A method of producing a sole assembly as in claim 11 wherein said actuation member comprises an elongate member.
 13. A method of producing a sole assembly as in claim 12 wherein said elongate member comprises at least one of a springboard, a semi-rigid component, or a rigid component.
 14. A method of producing a sole assembly as in claim 12 wherein said actuation member has one end fixed to a front section of said first sole component.
 15. A method of producing a sole assembly as in claim 11 wherein said material layer comprises a plurality of surface grooves.
 16. A method of producing a sole assembly as in claim 11 wherein said first sole component comprises part of a molded sole.
 17. A method of producing a sole assembly as in claim 11 further comprising the step of placing said first sole component and said second sole component into an item of footwear.
 18. A method of producing a sole assembly as in claim 11 further comprising the step of inserting said sole assembly into a prefabricated sole of an article of footwear. 